Pullback Assembly

ABSTRACT

A drill string with a bit at one end is used to dig an underground borehole. When the drill string exits the borehole at a surface exit point, a pullback adapter is used to interconnect the bit with an above-ground utility line. A drilling rig retracts the drill string from the borehole. As the drill string is pulled back through the borehole, the trailing utility line follows along its underground path. As the utility line is pulled through the borehole, the connector biases the utility line to the center of the borehole. Such biasing reduces the risk of ensnaring of the connector and utility line by the borehole walls during the pulling process.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Patent Application Ser. No. 62/281,399 tiled on Jan. 21, 2016, the entire contents of which are incorporated herein by reference.

FIELD

The invention relates to tools and methods for pulling a utility line through a borehole.

SUMMARY

An assembly is formed from a bit and a connector. The bit has a body and a plurality of hardened cutting elements supported on the body. The body has an internal passage extending therethrough. The connector extends through the passage. The connector is formed from a first member and a second member. The first member has an elongate neck and an enlarged head formed at one end of the neck. The second member is pivotally connected to the neck.

A kit is formed from a bit, a first connector element, and a second connector element. The bit has a body and a plurality of hardened cutting elements supported on the body. The body has an internal passage extending therethrough. The first connector element has an elongate neck and an enlarged head formed at one end of the neck. The elongate neck is sized to be closely received within the passage, The second connector element is configured for pivotal connection to the neck.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a pullback adapter formed from a shackle pivotally connected to a connector member.

FIG. 2 is a side elevation view of the connector member of FIG. 1.

FIG. 3 is a perspective view of the connector member of FIG. 1.

FIG. 4 is a perspective view of a bit.

FIG. 5 is an exploded view of a pullback assembly formed from the pullback adapter of FIG. 1 attached to the bit of FIG. 4.

FIG. 6 is a perspective view of the pullback assembly of FIG. 5 in which an upper side of the bit is shown.

FIG. 7 is a perspective view of the pullback assembly of FIG. 5 in which a lower side of the bit is shown.

FIG. 8 is a side elevation view of the pullback assembly with an alternate bit.

FIG. 9 is a side elevation view of a beacon connected to the pullback assembly of FIG. 8.

FIG. 10 is a perspective view of the beacon and assembly of FIG. 9.

FIG. 11 is a front elevation view of the pullback assembly of FIG. 5.

FIG. 12 is a system for pulling a utility line through a borehole using the pullback adapter, bit, and beacon shown in FIG. 9.

FIG. 13 is an enlarged view of a portion of the system of FIG. 12, showing the connection between the utility line and the pullback adapter.

DETAILED DESCRIPTION

Shown in FIG. 12 is a system 10 for pulling a utility line 12 through a borehole 14. The system 10 comprises a drilling rig 16, a drill string 18, a beacon 20, a bit 22, a pullback adapter 24, and the utility line 12. The utility line 12 may be a pipe, a cable, or any structure suitable for pulling through a borehole. Prior to installation, the utility line 12 may be stored on a spool 26.

The drill string 18 begins drilling the borehole 14 at a surface entrance point 28 and follows a path underground to a surface exit point 30. At the exit point 30 the pullback adapter 24 is connected to the bit 22 and the utility line 12. The drilling rig 16 pulls the drill string 18 back through the borehole 14. Since the pullback adapter 24 connects the utility line 12 to the drill string 18, the utility line 12 is pulled through the borehole 14 as the drill string 18 is retracted by the drilling rig 16.

With reference to FIGS. 1-3, the pullback adapter 24 comprises a first connector member 32. The first connector member 32 is formed from a strong and durable material, such as steel. The first connector member 32 has an elongate neck 34 and an enlarged head 36.

The elongate neck 34 has opposed first and second ends 38, 40. A passage 42 is formed in the first end 38 of the elongate neck 34 opposite the enlarged head 36. The first end 38 of the elongate neck 34 may terminate in a free end 44 that is curved, as shown in FIGS. 1-3. In another embodiment, the elongate neck 34 may terminate in a free end 44 having a planar surface. In the embodiment of FIGS. 1-3, the elongate neck 34 has the shape of a rectangular prism. However, in another embodiment the elongate neck 34 may have the shape of prism formed from a non-rectangular polygonal base, such as a triagonal prism, a pentagonal prism, or a hexagonal prism. In yet another embodiment, the elongate neck 34 may have the shape of a cylinder or a shape formed from a partial cylindrical base, such as a semicylinder.

The enlarged head 36 is formed at the second end 40 of the elongate neck 34. The enlarged head 36 has at least one flanged portion projecting radially outward from the elongate neck 34. At the flanged portion, the enlarged head 36 has a width larger than the width of the elongate neck 34. In the embodiment of FIGS. 1-3, the enlarged head 36 has a top surface 46 having the shape of a convex curve. However, the top surface 46 of the enlarged head 36 may have a shape that is flat or concave.

The pullback adapter 24 further comprises a second connector member attached to the first connector member 32. The second connector member is formed from a strong and durable material, such as steel. The second connector member may attach to the first connector member 32 through the passage 42 formed in the first end 38 of the first connector member 32. Preferably, the second connecter member is pivotally connected to the first connector member

As shown in FIGS. 1 and 5, the second connector member is a shackle 50 comprising a link 52 and a bolt 54. The link 52 has two arms 56 each having an opening 58. Preferably, the arms 56 are internally threaded within the openings 58.

Continuing with FIGS. 1 and 5, the bolt 54 has a shaft 60 and a head 62. The shaft 60 is sized to be received within the openings 58 of the arms 56. Preferably, the shaft 60 has a threaded portion 64 complementary to the arms' internal threads so that the bolt 54 may be threaded onto the link 52. Also preferably, the head 62 has a plurality of flat gripping surfaces 66 to facilitate threading the bolt 54 onto the link 52. The gripping surfaces 66 facilitate threading by providing purchase for a hand or tool that will rotate the bolt 54. The shackle 50 is assembled by passing the bolt 54 through the openings 58 of the arms 56. The assembled shackle 50 has an aperture 68 defined by the space enclosed by the link 52 and the bolt 54.

Referring to FIGS. 4-8, the bit 22 is formed from a strong and durable material, such as steel. The bit 22 has an elongate body 70 having an upper side 72 and a lower side 74. The bit 22 is characterized by a plurality of recessed areas 76 formed in the bit body 70. The body 70 is formed from a first leg 78 and a second leg 80. The first leg 78 has an upper surface 82, a lower surface 84, and a pair of tapering side surfaces 86. Preferably, the tapering side surfaces 86 converge to a point 88 at the first leg's free end. The second leg 80 has an upper surface 90 and a lower surface 92.

The first leg 78 and the second leg 80 join at a bend 94. The bend 94 creates a steering face so that the drilling direction can be changed. As shown in FIGS. 7 and 8, on the bit's lower side 74, the first leg 78 bends away from the second leg 80. The lower surface 84 of the first leg 78 and the lower surface 92 of the second leg 80 form an included angle θ measuring greater than 180 degrees and less than 220 degrees. Preferably, the included angle θ is 190 degrees.

With reference to FIGS. 4, 6 and 7, a plurality of passages 96 are formed in the body 70 and extend between the bit's upper and lower sides 72, 74. Preferably, the passages 96 are formed in both the first leg 78 and the second leg 80 of the bit body 70. As best shown in FIGS. 4 and 5, at least one of the passages 96 is a first leg passage 98 that is sized to closely receive the elongate neck 34 of the first connector member 32. The shape of the first leg passage 98 may be circular, or it may be complementary to the shape of the elongate neck 34. In the embodiment of FIG. 4, the first leg passage 98 has an oblong shape and is sized to closely receive the elongate neck 34 characterized by the shape of a rectangular prism.

Sizing the first leg passage 98 to closely receive the elongate neck 34 prevents the enlarged head 36 from entering the passage 98. Moreover, the tight fit between the passage 98 and the neck 34 combined with the oblong shape of the passage 98 prevents rotation of the rectangular neck 34 within the passage 98. Were the neck 34 permitted to rotate, the shackle 50 that it carries could move away from a centered position and toward the walls of the borehole 14. The shackle 50 and the utility line 12 could become mired in the borehole walls as a result.

Referring to FIGS. 4-8, the bit 22 further comprises a plurality of hardened cutting elements 100 supported on the body 70. The cutting elements 100 are formed from a strong and durable material, such as diamond or carbide. Preferably, the cutting elements 100 are polycarbonate diamond compact (PDC) cutters. The cutting elements 100 may be situated in the recessed areas 76 of the bit body 70. Preferably, the cutting elements 100 are positioned on both the first and second legs 78, 80 of the bit body 70.

As best shown in FIG. 5, a pullback assembly 102 is assembled by passing the elongate neck 34 of the first connector member 32 through the first leg passage 98 of the bit body 70. The shackle 50 is positioned so that the openings 58 in the arms 56 overlay the passage 42 in the elongate neck 34. The bolt 54 is passed through the openings 58 and the passage 42. Preferably, the shackle 50 is pivotally connected to the neck 34. Also preferably, the bolt 54 is threaded onto the link 52. However, the bolt 54 may be attached to the link 52 using any suitable fastener, such as a nut or a pin.

Shown in FIGS. 6-8 is the assembled pullback assembly 102 comprising the pullback adapter 24 attached to the bit 22. Preferably, the pullback adapter 24 is attached to the first leg 78 of the bit body 70. Also preferably, the enlarged head 36 of the first connector member 32 is situated on the upper side 72 of the bit body 70, and the shackle 50 is situated on the lower side 74 of the bit body 70. By situating the shackle 50 on the lower side 74 of the bit body's first leg 78, the shackle 50 is located on the side of the bit 22 that faces toward the surface exit point 30, which is the point from which the utility line 12 is pulled. Such configuration allows the shackle 50 and the utility line 12 to be biased toward the center of the borehole 14 during the pulling process. Such centering is advantageous because a centered shackle 50 and utility line 12 are less likely to become caught or mired within the borehole walls during the pulling process.

In FIGS. 9, 10, and 12, the pullback assembly 102 is shown attached to the beacon 20. The beacon 20 is carried by the drill string 18 so that the position of a downhole drilling tool can be monitored and adjusted. The beacon 20 is configured to transmit a low frequency dipole magnetic field, which can be detected by an above ground tracker. A tracker operator follows above the beacon 20 and transmits steering information back to a drill rig operator.

With reference to FIGS. 6 and 9-12, the beacon 20 has a housing 104 having an outer circumference 106 and opposed first and second ends 108, 110. The beacon's first end 108 is threaded onto the drill string 18. The beacon's second end 110 is connected to the bit body 70. The beacon 20 may be fastened to the bit body 70 by a plurality of fasteners passing through the plurality of passages 96 formed in the bit body's second leg 80. The bit body 70 may be positioned in oblique relationship to the longitudinal axis of the beacon 20.

FIG. 13 shows an enlarged view of the beacon 20, pullback assembly 102, and utility line 12 of FIG. 12 positioned with respect to a pulling axis 112 of the drill string 18. The pulling axis 112 is collinear with the force applied to the shackle 50 during the process of pulling the utility line 12 through the borehole 14. An included angle a is formed between the pulling axis 112 and the second leg 80. The bit body 70 may be positioned on the beacon 20 such that the included angle α is greater than 0 degrees and less than 25 degrees. Preferably, the included angle a is between about 8 and about 10 degrees.

Continuing with FIG. 13, an included angle β is formed between the pulling axis 112 and the bit body's first leg 78. The bit body 70 may be positioned so that the included angle β is greater than 0 degrees and less than 25 degrees. Preferably, the included angle is between about 18 and about 20 degrees.

With reference to FIGS. 6, 11, and 13, the shackle 50 is situated in the borehole 14 in collinear relationship with the pulling axis 112. The aperture 68 of the shackle 50 opens perpendicular to the pulling axis 112. A coupler 114 may be passed through the shackle's aperture 68 in order to connect the utility line 12 to the pullback adapter 24. The coupler 114 may be a shackle, a pulling grip, a pulling clevis, or any suitable pulling tool, such as a puller having a threaded portion configured for connection to the utility line. The coupler 114 may comprise a swivel.

FIGS. 11 and 13 shows the position of the shackle 50 relative to the borehole 14 and the beacon 20. The borehole 14 has a circumference 118 defined by the outermost reach of the bit's cutting elements 100. Because of the position of the bit body 70 relative to the beacon 20, the beacon's outer circumference 106 is not centered within the borehole's circumference 118. By situating the shackle 50 on the lower side 74 of the bit body 70, the shackle 50 is biased toward the center of the borehole 14, even though the beacon 20 is not centered within the borehole 14.

Shown in FIGS. 12 and 13 is the system 10 for pulling the utility line 12 through the borehole 14 in which the shackle 50 is positioned on the pulling axis 112. The pullback adapter 24 is connected to the bit 22, which is carried by the drill string 18. The pullback adapter 24 is also connected to the utility tine 12. As the drill string 18 is retracted, the utility line 12 is pulled through the borehole 14. Since the shackle 50 is centered on the pulling axis 112, the attached utility tine 12 is also biased to the pulling axis 112.

Changes may be made in the construction, operation and arrangement of the various parts, elements, steps and procedures described herein without departing from the spirit and scope of the invention as described in the following claims. 

What is claimed is:
 1. An assembly, comprising: a bit, comprising: a body having an internal passage extending therethrough; and a plurality of hardened cutting elements supported on the body; and a connector extending through the passage and comprising: a first member having an elongate neck and an enlarged head formed at one end of the neck; and a second member pivotally connected to the neck.
 2. The assembly of claim 1 in which the bit is carried by a drill string and in which the pivotal connection of the second member coincides with the longitudinal axis of the drill string.
 3. The assembly of claim 1 in which the neck is a rectangular prism.
 4. The assembly of claim 1 in which the second member comprises a shackle.
 5. The assembly of claim 1, the bit having first and second legs adjoined at a bend, in which the passage is formed in the first leg and in which the second leg is configured for connection to a drill string.
 6. The assembly of claim 5 in which each leg has opposed upper and lower surfaces in parallel relationship.
 7. The assembly of claim 6 in which the lower surface of the first leg and the lower surface of the second leg form an included angle of greater than 180 degrees and less than 220 degrees.
 8. The assembly of claim 7 in which the connector's second member is situated on the lower surface of the first leg.
 9. The assembly of claim 1 in which the first leg has a pair of tapering side surfaces joining together at a point opposite the bend.
 10. The assembly of claim 9 in which the side surfaces have hardened cutting elements.
 11. A system, comprising: a borehole formed in the ground; the assembly of claim 1 positioned within the borehole; and a utility line attached to the connector's second member.
 12. The system of claim 11 in which the utility line is a pipe.
 13. The system of claim 11 in which the utility line is a cable.
 14. A kit, comprising: a bit, comprising: a body having an internal passage extending therethrough; and a plurality of hardened cutting elements supported on the body; a first connector element having an elongate neck sized to be closely received within the passage and an enlarged head formed at one end of the neck; and a second connector element configured for pivotal connection to the neck.
 15. The kit of claim 14, the bit having first and second legs adjoined at a bend, in which the passage is formed in the first leg and in which the second leg is configured for connection to a drill string. 